Air flow system for appliances

ABSTRACT

A refrigerator includes a body defining a refrigerated compartment and an air duct, and an airflow system configured to circulate air between the refrigerated compartment and the air duct. The air flow system includes a fan configured to move air between the refrigerated compartment and the air duct, an evaporator configured to cool air passing through the air duct, and an air diverter assembly. The air diverter assembly includes a diverter provided at least partially within the air duct and configured to divert at least a portion of the air within the air duct into the refrigerated compartment, and a baffle provided at least partially within the refrigerated compartment and configured to direct air upward within the refrigerated compartment.

BACKGROUND

The present invention relates generally to the field of air flow systems for appliances, and more specifically, to an improved system for circulating and/or cooling air in a refrigerated appliance.

Refrigerated appliances are generally known. However, there are many challenges associated with effectively circulating and/or cooling air within refrigerated compartments of such appliances.

Accordingly, it would be desirable to provide an improved air flow system for appliances that provides one or more advantages over conventional systems.

SUMMARY

One embodiment relates to a refrigerator comprising a body defining a refrigerated compartment and an air duct; and an airflow system configured to circulate air between the refrigerated compartment and the air duct, the air flow system comprising a fan configured to move air between the refrigerated compartment and the air duct; an evaporator configured to cool air passing through the air duct; and an air diverter assembly comprising a diverter provided at least partially within the air duct and configured to divert at least a portion of the air within the air duct into the refrigerated compartment; and a baffle provided at least partially within the refrigerated compartment and configured to direct air upward within the refrigerated compartment.

Another embodiment relates to a method of circulating air within a refrigerated appliance, comprising directing air upward to a top portion of a refrigerated compartment; directing the air downward through an air duct in fluid communication with the refrigerated compartment; directing substantially all of the air over an evaporator to cool the air within the air duct; directing a first portion of the air out of the air duct and back into the refrigerated compartment; and directing the first portion of the air upward within the refrigerated compartment upon the air exiting the air duct.

Another embodiment relates to an air flow system for an appliance having a refrigerated compartment and an air duct in fluid communication with the refrigerated compartment, the air flow system comprising a fan configured to direct air upward through the refrigerated compartment and downward through the air duct; an evaporator provided within the air duct and configured to cool the air passing through the air duct; and an air diverter assembly provided at least partially within the air duct and configured to divide the air within the air duct into a first portion and a second portion, the first portion of air exiting the air duct via a first outlet and the second portion of air exiting a second outlet below the first outlet; wherein the evaporator is positioned below the fan and a static pressure column is formed within the air duct above the evaporator.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an appliance according to an exemplary embodiment.

FIG. 2 is a cross-sectional view of the appliance of FIG. 1 taken along line 2-2 according to an exemplary embodiment.

FIG. 3 is a cutaway perspective view of a portion of the appliance of FIG. 1 according to an exemplary embodiment.

FIG. 4 is a detailed cross-sectional view of a portion of the appliance of FIG. 1 according to an exemplary embodiment.

FIG. 5 is a front view of a wall portion of the appliance of FIG. 1 according to an exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring to FIG. 1, an appliance is shown as a refrigerator 10 according to an exemplary embodiment. According to various alternative embodiments, the teachings herein may extend to a variety of appliances such as a refrigerator, a freezer, a combination refrigerator/freezer, or other appliance. As shown in FIG. 1, refrigerator 10 includes a body 12, one or more doors 14, and an interior or refrigerated compartment 16 (e.g., a refrigerated space, a freezer space, a cooled space, etc.). One or more shelves 20 (e.g., removeable, slidable, and/or adjustable shelves, etc.) and one or more drawers 18 (e.g., crisper drawers, ripening drawers, storage drawers, etc.) may be provided within refrigerated compartment 16 to provide for storage of various food or other items.

Referring to FIG. 2, according to an exemplary embodiment, refrigerator 10 may include an air flow system 22 (an air circulation system, an air cooling/refrigeration system, an air treatment system, etc.). As shown in FIG. 2, air flow system 22 includes one or more inlets 26 (e.g., apertures, vents, etc.), a fan 24, an air duct 28 (e.g., a conduit, an air flow channel, a rear portion of the refrigerator, etc.), an evaporator 30, an air diverter assembly 32, and a lower outlet 40 (e.g., an aperture, vent, etc.). Air flow system 22 may include other features and components not shown herein according to various alternative embodiments.

As shown in FIG. 2, inlets 26 are provided at a top portion of refrigerated compartment 16 and permit fan 24 to draw air upward through refrigerated compartment 16 and into air duct 28. Inlets 26 may take any suitable form or shape, such as apertures, holes, slits, slots, and the like. Inlets 26 may be positioned at one or more suitable locations at or near a top portion of refrigerated compartment 16, and may be sized according to particular applications, fan size/placement, etc.

Referring further to FIG. 2, according to one embodiment, fan 24 is positioned above refrigerated compartment 16 and is configured such that air is directed or pulled upward through refrigerated compartment 16 and into an upper portion of air duct 28. Any suitable fan may be used to direct air through air flow system 22, and more than one fan may be used. According to various alternative embodiments, the position of fan 24 may be varied to suit a particular application.

As shown in FIG. 2, according to one embodiment, air duct 28 is provided within a rear wall of body 12 and generally extends from a top portion of refrigerator 10 to a bottom portion of refrigerator 10. In some embodiments, air duct 28 may have a height and width generally corresponding to the height and width of refrigerated compartment 16. In other embodiments, air duct 28 may take other shapes and/or sizes. For example, as discussed in greater detail below, air duct 28 may narrow and/or widen along its length to facilitate directing air across components such as an evaporator, etc.

According to one embodiment, evaporator 30 is provided within air duct 28. As shown in FIGS. 2-5, evaporator 30 may extend along all or a portion of the width of air duct 28. Any suitable evaporator may be used, and the position of evaporator 30 may be varied according to various exemplary embodiments. According to one embodiment, evaporator 30 has a width that is less than the width of air duct 28. One or more baffles 42 (e.g., air diverters, directers, etc.) may be provided on one or both sides of evaporator 30 to prevent air from passing around evaporator 30, and forcing substantially all of the air passing through air duct 28 to also pass over evaporator 30. This may help to ensure effective and efficient cooling of the air passing through air duct 28.

According to one embodiment, air diverter assembly 32 is provided at lease partially within air duct 28 and below evaporator 30. In some embodiments, air diverter assembly 32 may be provided proximate an outlet portion of evaporator 30. As shown in FIGS. 3-4, air diverter assembly 32 includes a diverter 34, an outlet 36, and a baffle 38. In some embodiments, one or more components of air diverter assembly 32 may be made and/or formed as an integrated component. According to one embodiment, diverter 34 may be an angled member or plate that extends downward within air duct 28 and directs (e.g., divides, distributes, etc.) a portion of the air flowing through air duct 28 toward outlet 36. Diverter 34 may extend along all or a portion of the width of air duct 28, and may be made of any suitable material, such as a variety of metals, polymers/plastics, and the like. Diverter 34 may be configured to achieve different distributions of air (e.g., to vary the amounts of air that exit/stay within air duct 28). According to one embodiment, diverter 34 is a generally longitudinally extending member having a first portion attached to a surface of air duct 28 and a second portion extending downward at an angle from the first portion.

Outlet 36 is positioned such that a portion of the air (e.g., a first portion) directed by diverter 34 re-enters refrigerated compartment 16. The remaining air (e.g., a second portion) flowing through air duct 28 continues to flow past outlet 36 downward through air duct 28. In one embodiment, outlet 36 includes a generally flat member having a series of generally parallel apertures (e.g., slits, slots, vents, etc.) that permit air to re-enter refrigerated compartment 16 in a generally uniform manner across the width of refrigerated compartment 16. The size and/or positioning of the various apertures along outlet 36 may be varied to adjust and/or control the air flow accordingly.

According to one embodiment, air entering refrigerated compartment 16 via outlet 36 is redirected upward by baffle 38. According to one embodiment, baffle 38 is provided wholly or partially within refrigerated compartment 16, and is shaped (e.g., formed, bent, etc.) to direct air from outlet 36 upward through refrigerated compartment 16. For example, a portion of baffle 38 may be generally “L”-shaped so as to direct air upward. According to various alternative embodiments, other shapes and/or sizes for baffle 38 may be utilized. As shown in FIG. 2 by arrows 46, air exiting outlet 36 is directed upward toward shelves 20 within refrigerated compartment 16. In various alternative embodiments, air exiting outlet 36 may redirected at, below, or above a shelf, drawer, or other component within refrigerated compartment 16.

Referring further to FIG. 2, a lower outlet 40 is provided at or near a bottom portion of air duct 28. After the air flowing through air duct 28 is divided by diverter 34, the air remaining in air duct 28 continues to travel downward toward lower outlet 40, where it re-enters refrigerated compartment 16. Lower outlet 40 may include one or more apertures that may be shaped, sized, and/or spaced to provide a desired air flow back into refrigerated compartment 16. For example, according to one embodiment, lower outlet 40 may include a single aperture extending generally along all or substantially all of the width of refrigerated compartment 16. As shown in FIG. 2 by arrows 46, air exiting lower outlet 40 is directed toward drawers 18 within refrigerated compartment 16. In some embodiments, additional baffles and/or diverters may be utilized to properly direct the air exiting from outlet 40.

In operation, air flow system 22 circulates and/or cools air within refrigerator 10 by drawing air upward though refrigerated compartment 16, and pushing the air downward through air duct 28 (and over evaporator 30) such that the air re-enters refrigerated compartment 16 via outlets 38, 40. According to one embodiment, as air exits fan 24 and travels downward through air duct 28 above evaporator 30, baffles 42 (see FIG. 5) act to force substantially all of the air within air duct 28 to travel over evaporator 30. In some embodiments, this causes a static pressure column (e.g., an area of increased air pressure, etc.) to develop generally at an area 44 (see FIG. 2) within air duct 28. Formation of the static pressure column may tend to cause the air flowing through air duct 28 to spread or “fan” out along the width of air duct 28 above evaporator 30 and flow generally evenly over the entirety of evaporator 30. This “fanning out” of the air within air duct 28 may facilitate heat transfer between the air and evaporator 30 and, subsequently, improve the overall energy efficiency of refrigerator 10.

After passing over evaporator 30, the air is strategically divided by diverter assembly 32. Diverter 34 divides the air between a first portion, which exits air duct 28 via outlet 36, and a second portion, which continues to travel through air duct 28 and exits via outlet 40. The first portion of air exiting air duct 28 via outlet 36 is directed upward into refrigerated compartment 16. The second portion of air exiting air duct 28 via outlet 40 is directed into a bottom portion of refrigerated compartment 16, where it is drawn upward by fan 24 and/or may be directed upward by one or more additional baffles. Eventually, both the first and second portions of air are drawn upward through refrigerated compartment 16 and back to fan 24.

The various features of the air flow system shown in the embodiments provided herein may provide various advantages over more traditional air flow systems. For example, many conventional air flow systems push/pull air downward through a refrigerated compartment, such that the air is pushed/pulled upward through an air duct and evaporator (e.g., in a manner reverse to that shown, e.g., in FIG. 2). In such traditional systems the air flowing through the air duct may tend to converge toward a middle portion of the air duct, resulting in inefficient use of the evaporator within the air duct. In contrast, the formation of the static pressure column in the present disclosure, resulting in part from the “reverse” air flow configuration (e.g., such that air flows upward through refrigerated compartment 16 and downward through air duct 28), may tend to increase the efficiency of the evaporator, and in turn, the refrigerator as a whole. Furthermore, utilizing an air diverter assembly to strategically divide the air flow may provide a more uniform temperature profile within the refrigerator, assist in more efficient cooling of food or other items on various shelves (e.g., shelves positioned at or near outlet 36) within the refrigerator, and avoid over-cooling of crisper drawers or other drawers (e.g., drawers positioned at or near outlet 40, that without diverter assembly 32 would receive all of the air flow from air duct 28).

It should be noted that the construction and arrangement of the elements of the air flow system as shown in the exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and/or omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the spirit of the present disclosure. 

1. A refrigerator comprising: a body defining a refrigerated compartment and an air duct; and an airflow system configured to circulate air between the refrigerated compartment and the air duct, the air flow system comprising: a fan configured to move air between the refrigerated compartment and the air duct; an evaporator configured to cool air passing through the air duct; and an air diverter assembly comprising: a diverter provided at least partially within the air duct and configured to divert at least a portion of the air within the air duct into the refrigerated compartment; and a baffle provided at least partially within the refrigerated compartment and configured to direct air upward within the refrigerated compartment.
 2. The refrigerator of claim 1, wherein the fan and evaporator are positioned such that a static pressure column of air is formed above the evaporator.
 3. The refrigerator of claim 1, wherein the fan is configured to pull air upward through the refrigerated compartment and push the air downward through the air duct and past the evaporator.
 4. The refrigerator of claim 3, wherein the air diverter assembly is provided below the evaporator assembly.
 5. The refrigerator of claim 1, wherein at least a portion of the diverter extends downward within the air duct and at least a portion of the baffle extends upward within the refrigerated compartment.
 6. The refrigerator of claim 1, wherein a first portion of air is directed out of a first outlet by the diverter and a second portion of air flows downward from the diverter through the air duct and exits the air duct at a second outlet at a bottom portion of the refrigerated compartment.
 7. The refrigerator of claim 1, further comprising at least one additional baffle provided within the air duct and proximate the evaporator, the at least one additional baffle configured to direct the air within the air duct such that substantially all of the air flowing through the air duct passes over the evaporator.
 8. The refrigerator of claim 1, wherein the fan is provided above the refrigerated compartment and the air duct is provided in a rear wall of the body of the refrigerator.
 9. The refrigerator of claim 1, wherein the diverter and the baffle each extend along substantially all of a width of the refrigerated compartment.
 10. A method of circulating air within a refrigerated appliance, comprising: directing air upward to a top portion of a refrigerated compartment; directing the air downward through an air duct in fluid communication with the refrigerated compartment; directing substantially all of the air over an evaporator to cool the air within the air duct; directing a first portion of the air out of the air duct and back into the refrigerated compartment; and directing the first portion of the air upward within the refrigerated compartment upon the air exiting the air duct.
 11. The method of claim 10, wherein directing the first portion of the air out of the air duct comprises providing a diverter within the air duct; and wherein directing the first portion of the air upward within the refrigerated compartment comprises providing a baffle within the refrigerated compartment.
 12. The method of claim 10, wherein at least a portion of the diverter extends downward within the air duct; and wherein at least a portion of the baffle extends upward within the refrigerated compartment.
 13. The method of claim 10, further comprising forming a static pressure column of air within the air duct and above the evaporator.
 14. The method of claim 10, wherein a second portion of the air in the air duct moves downward past the diverter and exits the air duct at a bottom portion of the air duct.
 15. An air flow system for an appliance having a refrigerated compartment and an air duct in fluid communication with the refrigerated compartment, the air flow system comprising: a fan configured to direct air upward through the refrigerated compartment and downward through the air duct; an evaporator provided within the air duct and configured to cool the air passing through the air duct; and an air diverter assembly provided at least partially within the air duct and configured to divide the air within the air duct into a first portion and a second portion, the first portion of air exiting the air duct via a first outlet and the second portion of air exiting a second outlet below the first outlet; wherein the evaporator is positioned below the fan and a static pressure column is formed within the air duct above the evaporator.
 16. The system of claim 15, wherein the air diverter assembly comprises a diverter provided at least partially within the air duct and a baffle provided at least partially within the refrigerated compartment.
 17. The system of claim 15, wherein at least a portion of the diverter extends downward within the air duct and is configured to direct air out of the air duct via the first outlet; and wherein at least a portion of the baffle extends upward within the refrigerated compartment and is configured to direct the first portion of air upward through the refrigerated compartment.
 18. The system of claim 15, wherein at least one additional baffle is provided within the air duct and at least partially above the evaporator, the at least one additional baffle directing the air within the air duct such that substantially all of the air flowing through the air duct passes over the evaporator.
 19. The system of claim 15, wherein the first and second outlets extend along substantially all of a width of the refrigerated compartment.
 20. The system of claim 15, wherein the fan is positioned above the refrigerated compartment and wherein the air diverter assembly is provided proximate to and below the evaporator. 